Vo l . 39 N o .

1 F e b r u a r y 2006

Development and Construction of LPG-FPSO

AWASHIMA Yuji : Manager, Engineering, IHI Marine United Inc.

AOKI Eiji : Technical Executive, IHI Marine United Inc.
ISHIKAWA Hiroki : Manager, Production Administration Department,
Kure Shipyard, IHI Marine United Inc.
WATANABE Kazuo : Manager, Ship & Offshore Design Department,
Kure Shipyard, IHI Marine United Inc.
MORITA Takashi : Manager, Ship & Offshore Design Department,
Kure Shipyard, IHI Marine United Inc.

IHI Marine United Inc. has developed, designed and constructed the world’s first LPG-FPSO, with the largest
storage capacity as a marine storage facility, by applying IHI’s excellent technology, design capability and highly
qualified construction skills. To meet the unique requirements of the LPG-FPSO, e.g. long operability at a site far
from dry docks, reduced vessel motions, cargo transfer between floaters, easiness of maintenance, high safety,
etc., IHI has applied serveral unique technologies such as the IHI-SPB tank system. Continuous operation of the
LPG-FPSO to commercialize the associated petroleum gas field will contribute toward reduction of CO2 emissions
to moderate climate change. The outline of the LPG-FPSO is described.

1. Introduction run by the Angolan government (SONANGOL), and as of

In November 2004, IHI Marine United Inc. (hereinafter May 2005, LPG-FPSO has been under trial operation
called IHIMU) delivered the world’s first LPG Floating using actual associated gasses in the aforementioned sea
Production, Storage and Offloading (LPG-FPSO) system area where it is installed.
to the owner, Single Buoy Moorings Inc. (hereinafter
called SBM) in Monaco (Fig. 1). This LPG-FPSO is
2. Background of development/construction
installed in Sanha Field, about 50 km off the Republic of The associated gasses (gasses such as propane and butane)
Angola, about 60 m deep, by means of single-point produced together with the crude oil have been
mooring and receives through pipelines the associated traditionally burnt on the vent tower or returned into the
gasses of propane and butane that are produced together original oil field to keep the natural flow from the oil/gas
with crude oil from the sea bottom. Then, LPG-FPSO
separates the associated gas into pure propane and butane,
with the process plant on the deck and cools them with the
refrigeration unit, then stores them in tanks in the hull, and
offloads the LPG into LPG carriers assigned from time to
time.
The LPG FPSO was ordered on the basis of the high
technology of IHI-SPB (Self-supporting Prismatic shape
IMO type B) tanks, our record in the construction of many
crude oil FPSO and FSO (Floating Storage and Offloading
systems) and the high evaluation of LPG-FSO (Escravos),
which has been operating continuously off Nigeria since
1997(1)-(3) without shutdown since its delivery by us. (IMO
stands for International Maritime Organization.)
This LPG-FPSO was delivered to SONASING, a joint
venture between SBM and a public oil corporation that is
Fig. 1 Overall view of LPG-FPSO

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Vo l . 39 N o . 1 F e b r u a r y 2006
field. Recently, however, from the viewpoints of
environmental issue, CO 2 reduction, and effective
utilization of energy resources, attention has been paid to
the movement of commercializing the associated gasses as
liquefied gas and transporting it to consumption areas. To
this end, gas separating equipment, reliquefaction and
refrigerating units and storage tank facilities are required.
Various systems are available for this purpose, such as
a system utilizing offshore platforms with land tanks and a
system in which all facilities are installed on land only.
Among them, the LPG-FPSO having storage tanks in the
hull structure and plant and reliquefaction/refrigerating
units on the deck allows maximum cost reduction. We
expect that its concept will increase in the future.
Especially, this LPG-FPSO system can be utilized in
marginal sea areas such as deep sea areas far away from
the land.
3. Required specifications and applicable
technologies
The main specifications and applicable technologies
required for realizing this LPG-FPSO are as follows.
3.1 High reliability to realize continuous operation
without docking for 20 years
We adopted cargo tanks of the IHI-SPB system to assure
the reliability over the life of the LPG-FPSO and also
adopted materials and paints superior in durability for
various units of equipment. As to the structural strength
including hull, tanks, and plant parts, we confirmed
adequate strength by conducting analyses based on the sea
conditions of the North Atlantic Ocean, which is severer
than those of the sea area of installation.
3.2 Technologies to avoid plant shutdown
In addition to the high specifications and high redundancy
of the plant itself, we were requested to prevent the plant
performance from deteriorating even in large waves that
are experienced once in 10 years. For this reason, we
pursued a type of hull shape to minimize hull motion
based on motion analysis and water tank testing. As a
result, we developed the optimum type of hull shape with
the rolling angle within 5 degrees. To reduce the hull
motion even in a combination of winds and waves
expected, we installed a 3 000 kW-class thruster for
maintaining the LPG FPSO direction. The generators and
other utilities were provided with sufficient redundancy.
3.3 Easy maintenance on the ocean
With the floating facility, many units of equipment are
arranged on a limited area. To facilitate maintenance on
the ocean, we fully investigated the arrangement elements
such as securing carry-out routes and repair areas of
various units of equipment. As a result, we installed 5
deck cranes and realized smooth maintenance
performance through optimum arrangement.
3.4 Securing safety
As to the plant part, cargo part, machinery part and related
10
equipment, piping, and apparatuses, we studied safety
systems called HAZID (Hazard Identification) and
HAZOP (Hazard and Operability) together with the
owners. We took various measures including pipe
arrangement with less accumulated damage, which will
allow emergency venting to discharge LPG. And we
provided heat-resistance for pressure vessels, and installed
blast-reducing panels on refrigeration/reliquefaction
rooms and designed strong accommodation structure
assuming an explosion at the plant part.
3.5 Challenge toward larger type
This LPG-FPSO has the largest cargo capacity of
any existing LPG ships in the world (maximum
about 85 000 m 3). We paid detailed attention in the
design analysis and construction.
4. Specifications of LPG-FPSO
4. 1 Outline
The principal particulars are shown below and the general
arrangement is shown in Fig. 2.
Length overall (Loa) 262.65 m
Length between perpendicular (Lbp)
230.00 m
Breadth (Mould) 49.00 m
Depth (Mould) 29.30 m
Design draft (Mould) 13.20 m
Scantling draft (Mould) 13.20 m
Cargo storage capacity (-50 deg. C)
135 000 m3
Cargo production capacity 5 940 m3/d
Cargo offloading capacity 5 400 m3/h
Deadweight Approx. 93 000 t
International gross tonnage 111 246
International net tonnage 33 374
The cargo tank consists of 6 tanks having a capacity of
135 000 m3 in total at -50 deg. C, and all the tanks can be
loaded with both propane and butane. The fore end
portion of the hull is provided with single point mooring
(turret) and accommodations for 60 persons. On the deck,
from the fore portion of the hull, propane refrigeration unit
room, propane/butane separating plant (depropanizer), and
butane refrigeration unit/reliquefaction unit room are
arranged. At the stern, the LPG discharging process vent
tower is installed.
The flag is Bahamas and the classification is ABS
(American Bureau of Shipping).
4.2 Plant & cargo part
The propane/butane mixture of room temperature/high
pressure (18 deg. C, 22 bar) is introduced into this LPG-
FPSO through undersea pipelines and risers and separated
into propane and butane by the depropanizer. Figure 3
shows the process flow.
Within the plant, the mixture is adjusted to 6.2 bar, 18
deg. C by the LPG surge vessel, and the sulfur content is
removed by the H2S scrubber, and then it is heated to 30
 Fig. 2 General arrangement

Fig. 3 Process flow of plant part

deg. C and separated into propane and butane of 17 bar,
100 deg. C by the fractionating column. The separated
propane and butane are cooled to -40 deg. C and -10 deg.
C, respectively, in the refrigeration unit room and stored
as liquefied gas (LPG) in the cargo tanks. The
refrigeration units for propane and butane have the
capacity of 50% of necessary capacity × 3 units and 100%
× 2 units, respectively.
The LPG in the tanks is vaporized due to heat ingress
from outside, but liquefied by the reliquefaction units and
returned into the tanks. The reliquefaction units have a
capacity of 100% of necessary capacity × 2 units for
propane, 100% × 1 unit for propane/butane, and 100% × 1
unit for butane. As the refrigerant, propane is used. The
depropanizer was made by NIKKI K.K. (JGC) in Japan
and the refrigeration/reliquefaction equipment by HGS
(Hamworthy Gas Systems AS) in Norway.
The LPG in the tanks is offloaded into LPG carriers
assigned from time to time by a maximum of 10 cargo
pumps. The pressurized butane can also be offloaded at a
rate of 550 m3/h.

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Vo l . 39 N o . 1 F e b r u a r y 2006

4.3 Hull structure & tank part Depropanizer Plant

As to the structure including hull, tanks, and plant deck,
the maximum stress and fatigue analyses (design life 30
years) were conducted assuming the marine conditions of
No.4 Deck Crane
North Atlantic (return period 20 years), marine conditions
at the site (return period 100 years), and marine conditions Ref./ Reliq. Unit Room
when towing, and sufficient strength was provided.
As aforementioned, the tanks are based on the IHI-SPB
system, a product of our design and construction
philosophy, and are completely different from the
conventional self-supporting prismatic shape IMO type A
LPG ships. Figure 4 shows the typical cross section of
the SPB tank. There has been so far no reports of damage
No.3 Hold
among tanks of the IHI-SPB system of LPG/LNG carriers,
No.4 Hold
or LPG-FSO constructed by IHIMU. Owners consider an
optimum system for FPSO required of continuous No.5 Hold

operation over a long period of time like this LPG-FPSO.
With this LPG-FPSO, the depropanizer plant,
Fig. 5 Structural model of plant part and hull part for FEM analysis
refrigeration unit room and reliquefaction unit room are
installed about 8 m or more above the deck. Since they are
very large structures, it is not proper to design them
separately from the hull. So, the structural analysis of
these large structures was made integral with the hull deck
portion. Figure 5 shows the entire analysis model.
Especially for the depropanizer plant installed on the hull
that has motion in waves, unlike land plants, IHIMU
conducted detailed strength checking, including fatigue
strength.
4.4 Hull part
When LPG is offloaded, an LPG carrier (maximum
85 000 m3) is moored alongside the LPG-FPSO, and the
fenders, winches and quick release hooks necessary for
the mooring are installed on the deck. When the
specifications of this equipment were decided, we
estimated the relative motion of this LPG-FPSO and LPG
carriers based on sea conditions for LPG offloading using
Deck Anti-rolling chock Deck girder
No.6 Hold
an analysis program developed by IHIMU to design for
securing safe operation. (4) In preparation for future
increase in transporting volume, the hull aft portion is
provided with tandem type mooring equipment and cargo
handling equipment to cope with LPG carriers of a
maximum 125 000 m3 class.
The piping design was made optimum using the three-
dimensional CAD system “Ajisai” that has been
developed independently by IHIMU, as in the case of the
hull design. Figure 6 shows the typical three-dimensional
piping arrangement on the deck.
The 60-person accommodations with luxurious interiors
assure comfortable living even for a long stay. The safety
is strengthened by adopting walls, windows and doors of
H-class structural fire protection (H-60). In designing the
helicopter deck installed at the top of the accommodation
space, tunnel tests were conducted by Research &
Development Division (Yokohama) of Ishikawajima-
Harima Heavy Industries Co., Ltd. (hereinafter called IHI)
to investigate the effects of the gust and exhaust gas from

Anti-flotation chock
Water ballast tank
Horizontal girder

Insulation

Access space

L
C
Support

Fig. 4 Cross section of IHI-SPB tank Fig. 6 Three dimensional piping arrangement on deck

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 Vo l . 39 N o . 1 F e b r u a r y 2006

the funnel, thereby realizing the optimum shape/arrangement.

Figure 7 shows the tunnel testing.
4.5 Machinery part
To cover all the necessary power supplies, boilers
firing marine gas oil/fuel gas (90 t/h ¥ 3 units),
turbine generators (9 000 kW ¥ 3 units), a diesel
generator (3 000 kW ¥ 1) and an emergency generator
(850 kW ¥ 1 unit) are equipped. As other utilities, an
inert gas generator, cooling water pumps (50% ¥ 3 units),
fire pumps (50% ¥ 2 units), deluge pumps (50% ¥ 2
units), and emergency fire pumps (50% ¥ 2 units) are
equipped.
4.6 Electrical & instrumentation part
Fig. 7 Tunnel test
This LPG-FPSO is equipped with a huge computer system
for centralized control of the entire LPG-FPSO (Monitor
and Control System: M&CS), which is located at the
FPSO control center (FCC) (Fig. 8). The M&CS consists
of a process control system to automatically control and
monitor units of equipment and safety shutdown system
for alarming and emergency shutdown.
Figure 9 shows the M&CS system diagram. With this
M&CS, continuous operation is realized by a minimum
number of persons.
5. Construction
The main hull and cargo tanks were constructed at the
IHIMU Kure Shipyard, depropanizer at IHI Kure-Shingu
Works, accommodation quarters at IHI AMTEC Co., Ltd.,
and pipe racks on the deck at IHI Aioi Works, and finally,
they were installed on this LPG-FPSO at IHIMU Kure Fig. 8 FPSO control center (FCC)
Shipyard. Especially the turret, depropanizer plant and

Depropanizer ：Process Control System

Exaquantum
：Safety Shutdown System PA/GA
… HIS 2 HIS 1

CS3000 CS3000
node node FIRE DETECTOR

…
FPSO Control Center ( FCC )

Prosaef Prosaef

EXT Alarm Plant Infomation Network

Remote Remote
node node

PC PC

Reliquefaction Refrigeration Switch Gear Machinery Room

Room ( SWGR ) Mach. Remote
HIS 8 HIS 7
Cont. Center
… YNT
*1 ( MRCC )

CS3000 node CS3000 node

Mulcom 176
Mulcom 177

…
…
FOR
Optical Fiber Cable

PLC for #1 propane Reliq. compressor PLC for #1 propane Ref. Compressor
R1 cont. C1 control
FOR
…

C2 PLC for #2 propane Ref. Compressor Protec. relay for

MVSW G 0 0 1
control
… …

R4 PLC for #4 butane Reliq. compressor C3 PLC for #3 propane Ref. Compressor
cont. control PLC f or # 1
boiler c o nt.
FOR

C4 PLC for #4 butane Ref. compressor

control GAS DETECTOR
FOR

C5 PLC for #5 butane Ref. compressor

control

Prosafe
CPU/
Prosafe
CPU/
… Prosafe
Prosafe Prosafe …
node node CPU/
node CP U/ remote
node node

Fig. 9 System diagram of monitoring and control system (M&CS)

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Vo l . 39 N o . 1 F e b r u a r y 2006
Fig. 10 Tank construction
Fig. 11 Installation of topsides
accommodation quarters were installed integrally using
the floating crane. Figure 10 and 11 show the tank
construction and plant installation, respectively.
The construction was started in November 2002. The
turret, accommodation quarters, and depropanizer plant
were installed from November 2003, and various
performances were adjusted and checked, and then at the
naming ceremony in June 2004, the ship was named
“SANHA LPG-FPSO.” In October, the gas trial was
completed, and delivery was made in November 2004.
Subsequently it was towed to the site, and since May
2005, has been under final adjustment and performance
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testing at the sea area of installation off Angola.
Concerning not only the design of FPSOs but also
construction and quality control, the applicable rules and
owner’s requirements were different between the hull part
and plant part. Therefore, adjustment and observation
were part of our efforts. Since this LPG-FPSO was
designed and constructed incorporating specifications and
safety check items of an international consortium
including Chevron Corporation (U.S.A.), the field project
implementing body, we also endeavored to control the
schedules of the construction.
6. Conclusion
This FPSO is the world’s largest LPG floating system in
the field including LPG ships as well as the world first
LPG-FPSO. We carried out the whole project from the
development to design and construction in a short period
of 33 months from the contract to the delivery, utilizing
the total technology and construction capability of
IHIMU. We sincerely hope that this LPG-FPSO will
continue its stable operation and contribute to the
progress of the owners and Republic of Angola and
prevention of global warming. And we expect that
projects based on the similar concept (LPG-FPSO, LNG-
FPSO, etc.) that can utilize our experience of this LPG-
FPSO will increase in the future.
REFERENCES
(1) M. Ximense, G. J. Adia and A. Abe : Design and
Construction of a Floating Storage and Offloading
Vessel Escravos LPG FSO, SNAME Transactions
Vol.105 (1997) pp.455-489
(2) E. Aoki, Y. Okumura, A. Abe, S. Yamashita and T.
Ishiguro : Technological Innovation of SPB Floating
Terminal GASTECH’98 Proceeding (1998)
(3) Y. Okumura, A. Ando and O. Ushirokawa : Outline
and Features of SPB LNG Carrier Technology,
Ishikawajima-Harima Engineering Review Vol.34
No.4 July 1994 pp.235-240
(4) H. Yokozawa, E. Aoki, S. Yamashita and R. Ishii :
Experimental Study on Relative Motions between
LNG FPSO and LNG Carrier in Waves, 15th Ocean
Engineering Symposium in 2000, Japan Society of
Naval Architects and Ocean Engineers